Final Project Report:

NSF PII award #0849008

October 15, 2011
James W. Beard, PI
Developing a Mobile, Robotic Welding System
Executive Summary:
This is the Final report for the project award 0849008 , Developing a Mobile Robotic Welding System covering
the period 2/1/09 through 10/15/11. This project includes the original STTR Phase II award and the TECP
supplement. This report serves as the final report for both activities.
Many industries such as large shipbuilding and site-based fabrication and construction do not lend themselves to
traditional assembly line robotic systems. Large military ships, for example, tend to be unique with each
successive ship manufactured having different characteristics. The size and scale of a typical ship combined with
the high costs associated with dry-docks or real-estate immediately adjacent to the launch location has led toward
a common manufacturing technique in which the structural components of the ship are assembled in multiple
locations with only the final assembly occurring in the most expensive location. We call these unstructured
environments because the building process is not regular (i.e., is not highly dimensionalized). Robotic systems in
these environments must be mobile, flexible and adaptable. This creates a unique set of challenges that this
project has addressed.
Mobile robotics (robotic systems capable of navigating through the environment to perform motion control tasks)
provides new opportunities to improve worker productivity in unstructured environments. Robotic Technologies
of Tennessee (RTT) and its University partner, Tennessee Technological University (TTU) have a history of
developing automated mobile robotic platforms in unstructured environments such as the power production and
shipbuilding industries. Under the NSF STTR program, Robotic Technologies of Tennessee (RTT) has developed
and commercialized a climbing mobile robotic welding system suited for welding in unstructured environments
such as shipyards or construction of large structures. This system is called the Mobile Robotic Welding System
(MRWS). The MRWS is capable of mechanizing weld processes while operating in inverted positions, even
upside down.
When compared to manual welding processes or track based automated systems, the MRWS increases
productivity, safety and quality. This system allows the weld technician to perform the weld process remotely
making the job safer and more comfortable for the operator. This tends to reduce work place injuries related to
repetitive motion and flying debris. In addition, the ability to control the welding from a control device allows the
worker to remain in a comparatively better ergonomic position which enables older and less physically healthy
welders to perform in their jobs longer. Finally, the MRWS better matches the expectations of younger
generations of workers giving industrial recruiters a better chance of attracting young workers to join the industry
(i.e., the industry is having trouble finding workers).
This system has been approved and qualified for the most stringent welding processes (NAVY requirements for
ships) by several Tier-I shipbuilding manufacturers. Two commercial versions of the MRWS have been
developed under the NSF STTR program. These systems are in use at the largest US shipyards. RTTs mobile
robotic welding systems have been a featured technology of the National Shipbuilding Research and have been
featured at several industry forums (Shiptech 2009 2011, Fabtech 2010, 2011).
The primary commercial focus for the RTT team is to achieve broad-based support from shipyards, demonstrated
through regular use, commitment to the product, and a target level of sales. As the project ends, RTT is well on
the way to achieving this broad-base support. We are currently negotiating with several large manufacturing
companies to identify an appropriate teaming agreement.
Commercialization and Dissemination: The team has been active in building shipyard support to move toward
partnership with a commercialized product as discussed above, with formal meetings held with new product

development personnel from ESAB and Illinois Tool Works, the parent company of Miller and Fronius. RTT has
been regularly invited to present at ShipTech. Shiptech is a avy sponsored meeting for all shipyards. At the
Shiptech 2011 meeting, RTT hosted a workshop on robotic automation for shipbuilding with nearly 30 shipyard
personnel in attendance.
In summary, the milestones planned for this project have been met. RTT has reached a commercialization stage
and is making sales and supporting product in the field. RTT has established one distributor in the Gulf-Coast
region. RTT is pursuing a teaming agreement with a larger manufacturer to expand the rate of growth of unit
sales and to target larger (national, worldwide) markets. A collection of photographs showing RTTs MRWS in
production are including in the following figures.
The remainder of this report will summarize the progress on all tasks associated with the project. This is first
summarized in a table that lists tasks, deliverables, dates completed and percentage complete. A detailed
discussion of each task and the work performed on each task is provided in appendix A, Summary of work on
project tasks.

Fig. 1 Advanced MRWS-100 in Production

MRWS-Mini
Light weight, portable, highly mobile system for remote welding

Operator performing weld remotely with Control Pendant Arc Viewing

1. Summary of Project Tasks and Subtasks:

The overall progress toward the project tasks are summarized in the following table, with the last two columns
indicated the percentage and date completed. The table is color coded as follows:
Tasks Completed
Tasks Underway
No Significant Progress Yet

Table I: Summary of Progress on Project Tasks:

Task

Task Description

Objective I: Advance Climbing Robot Platform

Perform advanced modeling and design on platform suspension
Task I.1
components to prepare for in-field climbing surface conditions.
Evaluate and optimize material performance in tandem with kinematic
Task I.2
design of the suspension components to survive extended in-field
conditions.
Design the MRWS platform to meet the shipbuilder requests of outdoor
Task I.3
operation and reduced system weight.
Create advanced model of magnetic fields created by the robot tractive
Task I.4
members and the weld arc, and use in advanced prototype design.
1. Enhanced prototype MRWS robot platform design meeting the
Deliverables
performance and requirements specified by the shipbuilders.
2. Multiple design options for locating welding torch manipulator
Objective II: Advance Design of Torch Manipulator
Extend the kinematic and dynamic models of the torch manipulator to
Task II.1
include the effects of compliance on the system.
Explore advanced inverse dynamic control algorithms and mechanical
Task II.2
designs to isolate dynamic disturbances at the torch tip.
Incorporate precise and repeatable torch work travel, depth, work angle,
Task II.3
and travel angle adjustments into the torch manipulator.
Design the torch manipulator for easy access by operators to the weld
Task II.4
torch
1. Torch manipulator design with enhancements to improve
Deliverables
performance and usability in the field.
Objective III: Advance Robot Control and Navigation System
Define the expected conditions the control system will have to overcome
Task III.1
in the field tests.
Develop a navigation and control algorithm to accommodate non-ideal
Task III.2
conditions defined in III.1.
Develop class of additional autonomous behaviors needed to handle inTask III.3
field conditions (e.g., alignment to weld seam, start and stop, obstacle
avoidance)
Implement the control and navigation system into the advanced MRWS
Task III.4
prototype
1. Advanced MRWS control and navigation system capable of
Deliverables
handling real-world conditions in manufacturing environment
Objective IV: Seam Tracking and Identification System
Using the lessons learned from the Phase I vision system, develop
Task IV.1
criteria to be met in the new vision system design.
Create basic overview of vision system design, select parts from COTS
Task IV.2
components as available, integrate with the MRWS platform.
Develop image processing algorithms (combination of commercial
Task IV.3
algorithms and modules developed by RTT) to identify the shape and
centerline of the weld seam.
Create interface between output from image system and robot control
Task IV.4
algorithm
Combine all hardware and the software developments and incorporate on
Task IV.5
to the advanced MRWS prototype

%
complete

date
compl
eted

100%

8/15/09

100%

8/15/09

100%

8/15/09

100%

8/15/09

1-100%
2-100%

8/15/09

100%

8/15/09

100%

8/15/09

100%

8/15/09

100%

8/15/09

100%

8/15/09

100%

8/15/09

100%

8/15/09

100%

8/15/09

100%

8/15/09

100%

8/15/09

100%

8/15/09

100%

12/15/09

100%

6/15/10

100%

8/30/09

100%

6/15/10

Deliverables

1. Hardware selection, image processing algorithms, system

embedded on robot platform
2. MRWS advanced prototype complete with tracking system based
on operator feedback

100 %

Objective V: Develop Human-Robot Interface (HRI) for Multi-DOF Welding System

Collect additional input on necessary control functions and desired
Task V.1
formats of HRI as well as the desired information to be reported from the
100%
robot system.
Incorporate hardware to allow the operator to setup and control the vision
Task V.2
100%
seam tracking system (tasks described Objective 4) from the HRI.
Design the layout of the HRI to effectively present all control parameters
Task V.3
100%
and minimize the overall size of the unit.
Incorporate into the HRI the ability for the robot to provide feedback to the
Task V.4
100%
operator during the weld process.
1. Design of rugged, compact HRI suitable for use with MRWS
Deliverables
100%
advanced prototype during the extended field tests.
Objective VI: Meet Weld Cert. Requirements and Remote Weld Viewing Capability
Select a camera system that offers a suitable picture of the welding
Task VI.1
100%
process in the immediate vicinity of arc.
Integrate the camera on to the MRWS, iterating to find the ideal position
Task VI.2
100%
yielding the best viewing angle for visual characterization of the weld.
Task VI.3
Collect input from welders and repeat VI.2 to satisfy their requirements.
100%
Provide the video data to the operator though integration with the robot
Task VI.4
100%
control pendant.
1. Identified camera system for MRWS platform.
100 %
Deliverables 2. MRWS platform with the camera integrated and feedback
provided in the robot control pendant.
Objective VII: Fabricate Advanced Prototypes of the MRWS Ready for Extended, In-Field Testing
Fabricate all components of the MRWS prototypes for the extended
Task VII.1
100%
field tests
Task VII.2
Assemble advanced MRWS prototype
100%
Deliverables 1. Advanced MRWS prototype (1-3) ready for field testing.
100%
Objective VIII: Prove MRWS in the Extended In-Field Tests
Task VIII.1 Develop the extended, in-field test plan.
100%
Perform first stage tests, (advanced in-lab tests), modify platform design
Task VIII.2
100%
as needed
Perform second-stage (primary) tests, Define details of environment for
Task VIII.3
100%
field testing.
Task VIII.4 Perform qualification tests on MRWS in-field
100%
Task VIII.5 Perform in field testing at commercial shipyard
100%
Task VIII.6 Modify platform design based on evaluation of in-field testing
100%
1.
Results from laboratory testing or MRWS.
2.
Results from field testing at commercial shipyard in a
Deliverables
production environment.
100%
3.
Enhanced prototype MRWS platform with extensive field
history.
Objective IX: Explore Future Commercialization Opportunities
Document the requirements for the new applications and design
Task IX.1
100%
modifications.
Develop a path to commercialization by building on current market
Task IX.2
100%
development.
1. Plan to upgrade and extend platforms to two advanced
Deliverables
applications.
100%
2. Commercialization plan for these two products
Objective X: Technology Transfer, Dissemination and Final Reporting
Disseminate project results through industry panels, appropriate
X.1
100%
conference or journal, market development activities
X.2
Prepare final reporting material
100%

6/15/10

3/15/10
3/15/10
3/15/10
3/15/10
3/15/10

6/15/10
6/15/10
6/15/10
12/15/10
3/15/10

3/15/10
8/30/10
8/30/10
3/15/10
5/15/10
6/30/10
3/30/10
2/15/11
3/1/11
3/1/11

6/1/11
6/1/11
6/1/11

8/1/11
10/15/11

Deliverables

1.
Executed dissemination plan
2. Final report

100%

10/15/11

TECP Objective I: Adapt MRWS system for control of inspection transducer

TECP I.1

Reconfigure existing
requirements

TECP I.2

100%

6/15/11

Reconfigure MRWS to adapt commercial transducers

100%

6/15/11

TECP I.3

Test positioning requirements

100%

6/15/11

TECP I.4

Evaluation system

100%

6/15/11

Adapt / Modify interpass cleaning system for inspection

application
1. Manipulator system able to meet standard UT positioning
requirements
2. Surface cleaning system integrated in system

100%

3/15/11

100%

6/15/11

TECP I.5
Deliverables

MRWS

manipulator

to

meet

NDE

TECP Objective 2: Modify system to reconfigure for various structures.

TECP II.1

Determine mobility needed for typical structures

100%

11/15/10

TECP II.2

Modify existing MRWS chassis to meet mobility requirements

100%

11/15/10

TECP II.3

Incorporate chassis control in operator interface

100%

11/15/10

Deliverables

1. Modified MRWS system with adaptive chassis

2. Test system on representative structres

100%

3/15/10

100%

3/15/11

100%

3/15/11

100%

8/15/11

Implement filtering algorithm to operate in real-time for

inspection data
Provide inspection results to operator during the inspection
process

100%

6/15/11

100%

8/15/11

Add on-board mechanism for in-situ location marking

100%

8/1/11

1. Onboard data filtering algorithm

2. Onboard system capable of marking specific location on a
structure

100%

8/15/11

TECP Objective III: Integrate data collection into the operator control system
TECP III.1

Define HMI requirements

TECP III.2

Modify existing MRWS

feedback

Deliverables

controller to

integrate

inspection

Operator control pendant designed for inspection operations

TECP Objective IV: Provide feature feedback to operator in real-time

TECP IV.1
TECP IV.2
TECP IV.3
Deliverables

TECP Objective V: Integrate Objectives I-IV into field-ready inspection platform

TECP V.1

Fabricate Inspection platform based on work from objectives 1-4

100%

10/15/11

TECP V.2

Test system and modify as needed

100%

10/15/11

TECP V.3

Demonstrate system use in field and deliver to Synterprise

100%

3/15/11

1. Fabricated Inspection System

2. Demonstration of advanced inspection capability

100%

10/15/11

Deliverable